Fill sheets and related fill pack assemblies

Abstract

A fill sheet for cooling heat transfer fluid in a cooling tower includes an air intake end, an air outlet end, a top edge and a bottom edge. The air outlet end is positioned opposite the air intake end along a lateral axis. The top edge connects the air intake end and the air outlet end and the bottom edge also connects the air intake end and the air outlet end. The bottom edge is positioned opposite the top edge along a vertical axis. A plurality of flutes extends generally parallel to the lateral axis between the air intake end and the air outlet end. An offset extends generally parallel to the vertical axis. A first flute of the plurality of flutes transitions from a first peak at a first side of the offset to a first valley at a second side of the offset.

I claim: 
     
       1. A fill sheet for assembly into fill packs comprised of pluralities of fill sheets, the fill sheet comprising:
 an air intake end; 
 an air outlet end positioned opposite the air intake end along a lateral axis; 
 a top edge connecting the air intake end and the air outlet end; 
 a bottom edge connecting the air intake end and the air outlet end, the bottom edge positioned opposite the top edge along a vertical axis; 
 an outlet side rib including a first outlet side rib segment having a top end and a first end and a second outlet side rib segment having a second end and a third end, the top end positioned proximate the top edge, the outlet side rib extending substantially parallel to the vertical axis, the first outlet side rib segment being laterally spaced from the second outlet side rib segment by a lateral spacing, the first outlet side rib segment overlapping with the second outlet side rib segment between the first end and the second end such that the first and second outlet side rib segments are intersected by the lateral axis between the first end and the second end; and 
 an inlet side rib including a first inlet side rib segment having a top end and a first end and a second inlet side rib segment having a second end and a third end, the top end of the first inlet side rib segment positioned proximate the top edge, the first inlet side rib segment being laterally spaced from the second inlet side rib segment by a lateral spacing between the first inlet side rib segment and the second inlet side rib segment, the first inlet side rib segment overlapping with the second inlet side rib segment between the first end of the first inlet side rib segment and the second end of the second inlet side rib segment such that the first and second inlet side rib segments are intersected by the lateral axis between the first end of the first inlet side rib segment and the second end of the second inlet side rib segment. 
 
     
     
       2. The fill sheet of  claim 1 , wherein the lateral spacing is between one-quarter and two inches. 
     
     
       3. The fill sheet of  claim 1 , wherein the outlet side rib is oriented at a pack angle relative to the vertical axis. 
     
     
       4. The fill sheet of  claim 3 , wherein the pack angle is zero to ten degrees. 
     
     
       5. The fill sheet of  claim 1 , wherein the outlet side rib further includes a third outlet side rib segment and a fourth outlet side rib segment, the third outlet side rib segment vertically aligned with the first outlet side rib segment and the fourth outlet side rib segment vertically aligned with the second outlet side rib segment, the inlet side rib further includes a third inlet side rib segment and a fourth inlet side rib segment, the third inlet side rib segment vertically aligned with the first inlet side rib segment and the fourth inlet side rib segment vertically aligned with the second inlet side rib segment. 
     
     
       6. The fill sheet of  claim 1 , wherein the first and second outlet side rib segments and the first and second inlet side rib segments have a generally arcuate-shaped cross-section. 
     
     
       7. The fill sheet of  claim 1 , wherein an interior section of the fill sheet includes a herringbone-shaped microstructure. 
     
     
       8. The fill sheet of  claim 7 , wherein the interior section is a heat transfer section and the heat transfer section includes a plurality of flutes extending through the heat transfer section and oriented to guide airflow in the heat transfer section generally along the lateral axis. 
     
     
       9. The fill sheet of  claim 1 , further comprising:
 an air exit side column of spacers positioned proximate the outlet side rib, the outlet side rib positioned between the air outlet end and the air exit side column of spacers. 
 
     
     
       10. The fill sheet of  claim 1 , further comprising:
 a transition feature oriented generally parallel to the vertical axis and positioned centrally between the air intake end and the air outlet end. 
 
     
     
       11. The fill sheet of  claim 1 , further comprising
 a honeycomb portion oriented generally parallel to the vertical axis and positioned proximate the air outlet end, the outlet side rib positioned in the honeycomb portion, the honeycomb portion oriented to direct working fluid toward a central portion of the fill sheet. 
 
     
     
       12. A fill sheet for assembly into fill packs comprised of pluralities of fill sheets, the fill sheet comprising:
 an air intake end; 
 an air outlet end positioned opposite the air intake end along a lateral axis; 
 a top edge connecting the air intake end and the air outlet end; 
 a bottom edge connecting the air intake end and the air outlet end, the bottom edge positioned opposite the top edge along a vertical axis; 
 an inlet side rib extending generally parallel to the vertical axis proximate the air intake end, the inlet side rib including a first inlet side rib segment and a second inlet side rib segment spaced laterally from the first inlet side rib segment at a lateral spacing, the first inlet side rib segment overlapping with the second inlet side rib segment between a first end of the first inlet side rib segment and a second end of the second inlet side rib segment such that the first and second inlet side rib segments are intersected by the lateral axis between the first end of the first inlet side rib segment and the second end of the second inlet side rib segment; 
 an outlet side rib extending generally parallel to the vertical axis proximate the air outlet end; and 
 a transition feature oriented generally parallel to the vertical axis and positioned centrally between the air intake end and the air outlet end. 
 
     
     
       13. The fill sheet of  claim 12 , wherein the outlet side rib is comprised of a plurality of outlet side rib segments, including first, second, third and fourth outlet side rib segments. 
     
     
       14. The fill sheet of  claim 13 , wherein the first and third outlet side rib segments are vertically aligned and laterally spaced from the second and fourth outlet side rib segments by a lateral spacing. 
     
     
       15. The fill sheet of  claim 12 , wherein the first inlet side rib segment and a third inlet side rib segment are vertically aligned and the second inlet side rib segment and a fourth inlet side rib segment are vertically aligned, the first and third inlet side rib segments spaced laterally relative to the second and fourth inlet side rib segments. 
     
     
       16. The fill sheet of  claim 12 , wherein the outlet side rib is positioned between an air exit side column of spacers and a plurality of air outlet end spacers, the air exit side column of spacers positioned in an interior section of the fill sheet and the air outlet end spacers positioned outside the interior section of the fill sheet. 
     
     
       17. The fill sheet of  claim 16 , wherein the air exit side column of spacers has a different configuration than the air outlet end spacers. 
     
     
       18. The fill sheet of  claim 12 , further comprising:
 a honeycomb portion oriented generally parallel to the vertical axis and positioned proximate the air outlet end, the outlet side rib positioned in the honeycomb portion, the honeycomb portion oriented to direct working fluid back into an interior section of the fill sheet. 
 
     
     
       19. The fill sheet of  claim 18 , wherein the interior section includes a herringbone-shaped microstructure. 
     
     
       20. The fill sheet of  claim 12 , further comprising:
 a plurality of flutes in an interior section of the fill sheet to guide airflow between the air intake end and the air outlet end. 
 
     
     
       21. The fill sheet of  claim 12 , further comprising:
 an air intake side column of spacers positioned proximate the air intake end; and 
 a plurality of air intake end spacers, the inlet side rib positioned between the air intake side column of spacers and the air intake end spacers. 
 
     
     
       22. The fill sheet of  claim 12 , further comprising:
 an intake honeycomb portion oriented generally parallel to the vertical axis and positioned proximate the air intake end, the inlet side rib positioned in the intake honeycomb portion, the intake honeycomb portion oriented to direct working fluid back into an interior section of the fill sheet. 
 
     
     
       23. The fill sheet of  claim 12 , wherein the inlet side rib, the outlet side rib, the air intake end, and the air outlet end are oriented at a pack angle relative to the vertical axis, the pack angle being zero to ten degrees.